Environmentally responsible insulating construction blocks and structures

ABSTRACT

Environmentally responsible insulating construction blocks and structures constructed primarily of recycled materials are disclosed. The environmentally friendly construction blocks and structures comprise shredded rubber tire pieces coated with silica fume, slag cement and cement, which are then mixed with water and formed in a mold. A layer of grout or a fireproof material may be disposed on one side of the environmentally responsible insulating construction block. The environmentally responsible insulating construction blocks provide high insulation as well as strength for applications such as green roofing, wall construction and green roofing decks. Environmentally friendly structures can be built by pouring the coated shredded rubber tire pieces into molds to form walls, and then to pour a layer of the coated shredded rubber tire pieces as a roof deck, thereby creating a self-supporting structure in a monolithic pour.

FIELD OF THE INVENTION

The invention relates to environmentally responsible insulatingconstruction blocks and structures constructed primarily of recycledmaterials. The environmentally responsible insulating constructionblocks and structures comprise shredded rubber tire pieces coated withsilica fume, slag cement and cement, which are then mixed with water andformed in a mold. In one embodiment, a layer of grout is disposed on oneside of the environmentally responsible insulating construction blockfor use in a roofing system. In one embodiment, a permeable layer of afireproof material is disposed on one side of the environmentallyresponsible insulating construction block. The environmentallyresponsible insulating construction blocks provide high insulation aswell as strength for applications such as green roofing deckconstruction. Environmentally friendly structures can be built bypouring the coated shredded rubber tire pieces into molds to form walls,and then to pour a layer of the coated shredded rubber tire pieces as aroof deck, therefore forming an entire structure in one singlemonolithic pour.

BACKGROUND

In many developed countries the construction and use of buildings is aleading consumer of energy and producer of greenhouse gas emissions.Sustainable architecture seeks to minimize the negative environmentalimpact of buildings by efficiency and moderation in the use ofmaterials, energy, and development space. Sustainable architecture usesa conscious approach to energy and ecological conservation in the designof the built environment

Green building (also known as green construction or sustainablebuilding) refers to both a structure and the using of processes that areenvironmentally responsible and resource-efficient throughout abuilding's life-cycle, from siting to design, construction, operation,maintenance, renovation, and demolition. Green building rating systemssuch as BREEAM (United Kingdom), LEED® (United States and Canada), DGNB(Germany), CASBEE (Japan), and VERDEGBCe (Spain) help consumersdetermine a structure's level of environmental performance. Thesesystems award credits for building features that support green design incategories such as location and maintenance of building site,conservation of water, energy, and building materials, and occupantcomfort and health. The number of credits generally determines the levelof achievement. Additionally, green building codes and standards, suchas the International Code Council's draft International GreenConstruction Code, are rules created by standards developmentorganizations that establish minimum requirements for elements of greenbuilding such as materials or heating and cooling.

Leadership in Energy and Environmental Design (LEED®) is a set of ratingsystems for the design, construction, operation, and maintenance ofgreen buildings in the United States and Canada which was developed bythe U.S. Green Building Council (USGBC). LEED® certification of abuilding is recognized across the globe as the premier mark ofachievement in green building. LEED®-certified buildings cost less tooperate, reducing energy and water bills by as much as 40%. Businessesand organizations across the globe use LEED® to increase the efficiencyof their buildings, freeing up valuable resources that can be used tocreate new jobs, attract and retain top talent, expand operations andinvest in emerging technologies.

The intent of LEED® is to provide a standard certification process thatregisters buildings constructed with environmental performance,efficiency, and occupant health and well-being as primary goals.Buildings receive points towards varying levels of certification basedon the set of categories established by the USGBC. For example, pointsare awarded with respect to the following features:

Site development that protects or restores habitat or that maximizesopen space;

Storm water design to minimize impervious surfaces;

Heat island effect that uses alternative surfaces and nonstructuraltechniques to reduce imperviousness and promote infiltration, reducingpollutant loadings and use of vegetated roofs;

Water efficiency by use of green roofing system without permanentirrigation or that minimizes potable consumption;

Energy and optimization by establishing the minimum level of energyefficiency for the building and systems; and

Materials and resources that reuse building materials and products toreduce demand for virgin materials and reduce waste, use of recycledcomponents and use of regional material that has been manufactured andassembled within 500 miles of the building.

Green roofing systems installed on 50% of more of a roof surfacevirtually guarantees 2 point toward LEED® certification, and cancontribute an additional 7+ points. This is almost 20% of the totalnumber of points needed for a building to be LEED®-certified.

Low slope roofing systems have been developed for use with buildings.Low slope roofing systems commonly include a structural deck made ofmetal or concrete that is covered with a layer of insulation, and theinsulation is then covered with a waterproof membrane. A commercial lowslope roof system may use single-ply membranes of pre-fabricated sheetsrolled onto the roof and attached with mechanical fasteners, adheredwith chemical adhesives, or held in place with ballast such as gravel,stones, or pavers; built-up roofs consisting of a base sheet, fabricreinforcement layers, and a dark protective surface layer; modifiedbitumen sheet membranes having one or more layers of plastic or rubbermaterial with reinforcing fabrics, and surfaced with mineral granules ora smooth finish; and spray polyurethane foam roofs constructed by mixingtwo liquid chemicals together that react and expand to form one solidpiece that adheres to the roof then having a protective coating such asmetal or tile placed over the polyurethane.

Low slope roofing insulation became more prevalent during the 1960's andforward as increasingly more buildings became air conditioned and as thecost of energy, both for heating and cooling rose dramatically.Currently insulation levels may exceed R30 as specified by code orbecause of the building's use and geographic location.

Insulated panels are known to be used on wall and roof buildingapplications to form part or all of the building envelope. An insulationpanel typically has opposing inside and outside surfaces with aninsulating foam core adhered between the surfaces. The panel can then bemounted onto support structures to form the wall or roof application ina building.

In the luxury real estate market, buyers in high rise structures seekliving spaces on the roof of the structure for providing such amenitiesas gardens and pools. A green roof, or living roof, is a roof of abuilding that is partially or completely covered with vegetation and agrowing medium, planted over a waterproofing membrane. It may alsoinclude additional layers such as a root barrier and drainage andirrigation systems.

One disadvantage of green roofs is the additional mass of soil andretained water that can place a large strain on the structural supportof a building. Some types of green roofs also have more demandingstructural standards such as in seismic and hurricane-prone regions ofthe world. Some existing buildings cannot be retrofitted with certainkinds of green roofing because of the weight load of the substrate andvegetation exceeds permitted static loading. For example, the weight ofa green roof caused the collapse of a large sports hall roof in HongKong in 2016.

One known way to provide rooftop green spaces for high rises is throughthe use of Inverted Roof Membrane Assemblies (IRMA), also called aProtected Membrane Roof system (PMR) or a Built-up-Roof (BUR) system. InIMRAs, typically a waterproofing membrane is adhered to the roofstructure of the building, then a protective moisture resistantinsulation layer is laid to protect the membrane from atmosphericdegradation such as sun, wind and rain, and also foot traffic. A layerof mesh may be laid to filter for debris, and the insulation layer isheld down with a form of ballast such as gravel wooden decking or pavingstones. A camber, or slope, of the roof is created during constructionto carry water to a roof drain. An example of a IRMA is shown in FIG. 1.

Tire recycling or rubber recycling is the process of recycling vehicles'tires that are no longer suitable for use on vehicles due to wear orirreparable damage. These tires are a large and difficult source ofwaste due to the large volume produced, and the fact they contain anumber of components that are ecologically problematic. In the UnitedStates alone the Environmental Protection Agency (EPA) estimates thatroughly 300 million scrap tires are generated annually. Over 60 millionof these tires end up in landfills, ocean, lakes, greatly harming ourenvironment. Local recycling facilities are having a very difficult timedealing with this problem because of the enormous quantities of tiresbeing generated each year and with only so many limited re-use optionsavailable to them.

The same characteristics that make waste tires problematic—cheapavailability, bulk, and resilience—also make them attractive targets forrecycling. Tires are known to be recycled for use on basketball courts,in hot melt asphalt, for increasing burning value of RDF in incinerationplants and new shoe products.

SUMMARY OF THE INVENTION

The invention relates to an environmentally responsible insulatingconstruction block for green roofing and decking applications as well asenvironmentally friendly structures. The environmentally responsibleconstruction blocks provide high insulation as well as strength forapplications such as green roofing and decking construction.Additionally, environmentally friendly structures can be built in onesingle monolithic pour.

In one embodiment of the invention, the environmentally responsibleinsulating construction blocks are adhered to a waterproof membrane thatis adhered to the top layer of an insulating layer of a roofing systemthat is adhered to a roof substrate of a building to provide a greenroofing application.

In one embodiment, the environmentally responsible insulatingconstruction blocks are provided in side by side relation to similarenvironmentally responsible insulating construction blocks and adheredto a roof substrate to provide an insulating layer for a membraneroofing system. A waterproof membrane is glued to the top of theenvironmentally responsible insulating construction blocks, and theenvironmentally responsible insulated construction blocks are thenadhered to the waterproof membrane for use as a green roofingapplication.

In one embodiment, environmentally responsible insulating constructionblocks are layered with a top layer of permeable fireproof material foruse as a green decking application.

In one embodiment, a plurality of environmentally responsible insulatingconstruction blocks is adhered to a waterproof membrane that is adheredto the top layer of an insulating layer of a roofing system that isadhered to a roof substrate of a building to provide a green roofingapplication. A second layer of environmentally responsible insulatingconstruction blocks having a top layer of a permeable fireproof materialare adhered to the top layer of the green roofing application for use asa green decking application. In one embodiment, the tops of theenvironmentally responsible insulating construction blocks that form thegreen roofing application are tapered to create a “slope to drain”roofing system. The bottom surfaces of the environmentally responsibleinsulated construction blocks for green decking application are taperedto correspond to the tapering of the tops of the environmentallyresponsible insulated construction blocks for green roofing application.The slope of the tops and bottoms of the environmentally responsibleinsulating construction blocks direct liquids to a roof drain. Thepermeability of the environmentally responsible insulating constructionblocks for green decking application allows for water to pass throughand be directed to the roof drain.

The environmentally responsible insulating construction blocks for greendecking application comprise a plurality of shredded rubber tire piecesdry mixed with silica fume, slag cement and cement until the shreddedrubber tire pieces are coated. Water is then added to the dry coatedshredded rubber mixture. A layer of a permeable fireproof material isplaced in the mold and the wetted shredded rubber tire mixture is placedin the mold on top of the layer of permeable fireproof materialwhereupon it dries into an environmentally responsible insulatingconstruction block for green decking application. The driedenvironmentally responsible insulating construction block for greendecking application comprises an open matrix from the top through whichliquids such as water can freely pass.

In one embodiment, the permeable fireproof material comprises expandedslate.

The environmentally responsible insulating construction blocks for greenroofing application comprise a plurality of shredded rubber tire piecesdry mixed with silica fume, slag cement and cement until the shreddedrubber tire pieces are coated. Water is then added to the dry coatedshredded rubber mixture. A layer of grout may be placed in the mold andthe wetted shredded rubber tire mixture is placed in the mold on top ofthe layer of grout whereupon it dries into an environmentallyresponsible insulating construction block for green roofing application.The dried environmentally responsible insulating construction block forgreen roofing application comprises an open matrix. In one embodiment,the environmentally responsible insulating construction blocks canfurther comprise insulation foam disposed in the interior open matrix ofthe blocks.

In one embodiment, the coated shredded rubber tire mixture is pouredinto molds to form walls for a structure. In one embodiment, the coatedshredded rubber tire mixture is poured directly onto a scarifiedconcrete slab. In one embodiment, the coated shredded rubber tiremixture is poured on top of a layer of grout that has been placed on topof a scarified concrete slab. Rods are inserted through the length ofthe molds so that a top can be placed on the poured coated shreddedrubber tire mixture for compression while it dries. The top may be aplywood sheet.

In one embodiment, a layer of coated shredded rubber tire mixture ispoured on a plywood layer to form a roof covering. A plurality of rodsextends upward from the plywood layer to allow for a top to be placedover the poured coated shredded rubber tire mixture to compress it whileit dries.

BRIEF DESCRIPTION OF THE DRAWINGS.

The invention will now be described, by way of example, with referenceto the accompanying drawings, in which like numerals refer to likeelements.

FIG. 1 depicts the construction of a typical IRMA.

FIG. 2 depicts an environmentally responsible insulating constructionblock for green decking application according to one embodiment of theinvention.

FIGS. 3A-3E depict various embodiments of an environmentally responsibleinsulating construction block for green roofing application topped withan environmentally responsible insulating construction block for greendecking application.

FIGS. 4A-4K depict the steps of manufacturing an environmentallyresponsible insulating construction block for green decking applicationaccording to one embodiment of the invention.

FIGS. 5A-5H depict the steps undertaken in the construction of astructure made entirely of an environmentally responsible insulatingmixture of shredded rubber tire pieces coated with silica fume, slagcement and cement, and mixed with water prior to pouring the structure.

FIG. 6 depicts a roofing system comprising an environmentallyresponsible insulating construction block for green roofing applicationaccording to one embodiment of the invention.

FIGS. 7A-7G depict the steps of manufacturing an environmentallyresponsible insulating construction block for green roofing applicationaccording to one embodiment of the invention.

DETAILED DESCRIPTION OF THE INVENTION.

The invention relates to environmentally responsible insulatingconstruction blocks for green roofing and green decking applications.The environmentally responsible insulating construction blocks providehigh insulation as well as strength. Additionally, environmentallyfriendly structures can be built in one single monolithic pour.

In one embodiment of the invention, an environmentally responsibleinsulating construction block is provided for use for green roofingapplications. In this embodiment, the environmentally responsibleinsulating construction block is adhered to a waterproof membrane thatis adhered to the top layer of an insulating layer of a membrane roofingsystem that is adhered to a roof substrate of a building.

Environmentally responsible insulated construction blocks used for greenroofing applications comprise coated shredded rubber pieces having a toplayer of dried grout that is dried into a block comprising a bottomsurface, a top surface, the top surface comprising the grout layer, andfour side surfaces substantially perpendicular to the top surface andthe bottom surface, wherein the environmentally responsible insulatingconstruction blocks have a thickness defined by the distance between thetop surface and the bottom surface. The environmentally responsibleinsulated construction blocks comprising the coated shredded rubbermixture and dried grout are glued or otherwise adhered to a roofsubstrate of a building to provide an insulating layer for a membraneroofing system. A waterproof membrane is glued or otherwise adhered tothe grout layer of the environmentally responsible insulatedconstruction blocks. The environmentally responsible insulatingconstruction blocks of the invention comprising the coated shreddedrubber mixture and a top layer of dried grout are adhered to thewaterproof membrane. In one embodiment, the tops of the environmentallyresponsible insulated construction blocks may be shaped in a manner toinduce liquid flow toward a desired direction, for example to a drain.

In one embodiment, the environmentally responsible insulatingconstruction blocks for green roofing application are provided in sideby side relation to substantially similar environmentally responsibleinsulating construction blocks and adhered to a roof substrate toprovide an insulating layer for a membrane roofing system. A waterproofmembrane is glued to the top of the environmentally responsibleinsulating construction blocks for green roofing application, and theenvironmentally responsible insulated construction blocks for greenroofing application are then adhered to the waterproof membrane to forma green roof.

In one embodiment of the invention, an environmentally responsibleinsulating construction block is provided for use for green deckingapplications. In this embodiment, the environmentally responsibleinsulating construction block is adhered to a surface to provide a greendeck to which growing media or tiles may be adhered. The environmentallyresponsible insulating construction blocks for green decking applicationcomprise a porous matrix through which water can flow freely.

Environmentally responsible insulated construction blocks used for greendecking applications comprise coated shredded rubber pieces that aredried into a block comprising a bottom surface, a top surface, the topsurface comprising a permeable fireproof material, and four sidesurfaces substantially perpendicular to the top surface and the bottomsurface, wherein the environmentally responsible insulating constructionblocks for decking application have a thickness defined by the distancebetween the top surface and the bottom surface. The environmentallyresponsible insulated construction blocks for decking applicationcomprising the coated shredded rubber mixture and permeable waterproofmaterial are glued or otherwise adhered to a substrate of the roof of abuilding to provide a porous deck to which growing media and/or paversand tiles can be adhered.

In one embodiment, the permeable fireproof material comprises expandedslate.

In one embodiment, a plurality of environmentally responsible insulatingconstruction blocks for roofing application is adhered to a waterproofmembrane that is adhered to the top layer of an insulating layer of aroofing system that is adhered to a roof substrate of a building toprovide a green roof. A second layer of environmentally responsibleinsulating construction blocks having a top layer of a permeablefireproof material are adhered to the top layer of the green roof toform a green deck. In one embodiment, the tops of the environmentallyresponsible insulating construction blocks for green roofing applicationare tapered to create a “slope to drain” roofing system. The bottomsurfaces of the environmentally responsible insulated constructionblocks for green decking application are tapered to correspond to thetapering of the tops of the environmentally responsible insulatedconstruction blocks for green roofing application. The slope of the topsand bottoms of the environmentally responsible insulating constructionblocks for roofing application and decking application direct liquids toa roof drain. The permeability of the environmentally responsibleinsulating construction blocks for green decking application allows forwater to pass through and be directed to the roof drain.

In one embodiment, the shredded rubber tire pieces comprise shreddedtires. In one embodiment, the shredded rubber tire pieces are shreddedto a size such that the steel from the tires is removed but nylonremains in the shredded rubber tire pieces. In one embodiment, theshredded rubber tire pieces are approximately 2 inches nominal size. Inone embodiment, the shredded rubber tire pieces have a size greater thanapproximately ½ inch but smaller than approximately 2 inches. In oneembodiment, the shredded rubber tire pieces have a size greater thanapproximately 1 inch but smaller than approximately 2 inches.

In one embodiment of the invention, the environmentally responsibleinsulating construction blocks have a thickness (measured from thebottom surface to the top surface) ranging from around 2 inches toaround 20 inches, with length and width (measured along the sidesurfaces) of around 12 inches square. Other dimensions of theenvironmentally responsible insulating construction blocks may beconstructed in accordance with the principles of the invention and thesepreceding dimensions are listed as examples only and are not intended inany way to limit the invention.

In one embodiment, the green roof and green deck made from theenvironmentally responsible insulated construction blocks meet buildingcodes designed to withstand severe weather conditions, such as strongwinds. 101.4.2 Florida Building Code (FBC), for example, applies to “theconstruction, erection, alteration, modification, repair, equipment, useand occupancy, location, maintenance, removal and demolition of everypublic and private building, structure . . . ” and sets forthrequirements for buildings to withstand wind forces resulting fromdesign wind speeds. In Broward County, Florida, buildings must withstandwind forces of 140 mph, and in Miami-Dade County, Florida, buildingsmust withstand wind forces of 146 mph. Other standards exist, forexample ASCE (American Society of Civil Engineers)-7 and Florida Statute553.844 setting forth Building Construction Standards titled “Windstormloss mitigation; requirements for roofs and opening protection.” Thesestandards may also apply to roof and deck replacement.

In one embodiment, the coated shredded rubber tire mixture is pouredinto molds in a monolithic pour to form walls for a structure. In oneembodiment, the coated shredded rubber tire mixture is poured directlyonto a scarified concrete slab. In one embodiment, the coated shreddedrubber tire mixture is poured on top of a layer of grout that has beenplaced on top of a scarified concrete slab. Rods are inserted throughthe length of the molds so that a top can be placed on the poured coatedshredded rubber tire mixture for compression while it dries. The top maybe a plywood sheet.

In one embodiment, a layer of coated shredded rubber tire mixture ispoured on a plywood layer to form a roof covering. A plurality of rodsextends upward from the plywood layer to allow for a top to be placedover the poured coated shredded rubber tire mixture to compress it whileit dries.

Turning to the figures, FIG. 1 depicts a typical IRMA 100. A slopedinsulating roofing layer 110 is adhered to a roofing substrate 120. Awaterproof membrane 130 is adhered to the top of the roofing layer 110.Insulation 150 is placed on top of drainage space 140. A drainage andvent layer 160 is formed on top of the insulation 150, which may includea root barrier 165. Filter fabric 170 can be placed on insulation 160. Adeck can then be formed using gravel 180 and concrete pavers 190. Thedeck may also include a planting medium 195.

FIG. 2 depicts an environmentally responsible insulating constructionblock for green decking application 200 comprising a bottom surface 201;a top surface 202 having a permeable layer of a fireproof material 215;and four side walls 203. Shredded rubber tire pieces 205 have beencoated with silica fume, slag cement and cement and then mixed withwater and dried to form an open matrix in the interior ofenvironmentally responsible insulating construction block for greendecking application 200. In one embodiment, the permeable layer offireproof material 215 comprises expanded slate which has been coatedwith silica fume, slag cement and cement and then mixed with water, thenplaced in a mold whereupon the wetted shredded rubber mixture is placedin the mold and dried to form the environmentally responsible insulatingconstruction block for green decking application 200.

FIGS. 3A-3E depict various embodiments of an environmentally responsibleinsulating construction block for green roofing application topped withan environmentally responsible insulating construction block for greendecking application.

FIG. 3A depicts a side view of an environmentally responsible insulatingconstruction block for green roofing application topped with anenvironmentally responsible insulating construction block for greendecking application. A plurality of environmentally responsibleinsulating construction blocks for green roofing application is adheredby a layer of adhesive 312 to a layer of insulation 325 on top of aroofing substrate 320 to form a green roof 310. A waterproof membrane330 is adhered to the top of the green roof 310. A plurality ofenvironmentally responsible insulating construction blocks for greendecking application that have been topped with a permeable fireproofmaterial 345, such as coated expanded slate, are placed on top of alayer of grout 355 to adhere to the waterproof membrane 330 to form agreen deck 350. Green deck 350 may comprise growing media 380 and/orpavers or tiles 390. Green roofing application 310 may comprise growingmedia 380 and/or pavers or tiles 390. Green deck 350 may includeplanting media 395 and/or artificial turf 397. The top surface of greenroof 310 may be sloped to drain water that passes through green deck 350toward a drain 335.

FIG. 3B depicts a cut-away view of one embodiment of an environmentallyresponsible insulating construction block for green roofing applicationtopped with an environmentally responsible insulating construction blockfor green decking application comprising turf. Environmentallyresponsible insulating construction blocks for green roofing applicationare adhered by a layer of grout 312 to a waterproof membrane 325 on topof a roofing substrate 320 to form a green roof 310. A waterproofmembrane 330 is adhered to the top of the green roof 310. A plurality ofenvironmentally responsible insulating construction blocks of coatedshredded rubber tire pieces for green decking application that have beentopped with a permeable fireproof material 345, such as coated expandedslate, are placed on top of a layer of grout 355 to adhere to thewaterproof membrane 330 for use as a green deck 350. Green deck 350 maycomprise growing media 380 and/or pavers or tiles 390. Green roof 310may also comprise growing media 380 and/or pavers or tiles 390. Greendeck may include artificial turf 397 that can be bonded to the top ofthe layer of fireproof permeable material 345.

FIG. 3C depicts a cut-away view of one embodiment of an environmentallyresponsible insulating construction block for green roofing applicationtopped with an environmentally responsible insulating construction blockfor green decking application comprising turf. Environmentallyresponsible insulating construction blocks for green roofing applicationare adhered to a layer of a waterproof membrane 325 on top of a roofingsubstrate 320 for use as a green roof 310. In this embodiment, aninsulation board 327 is adhered to a waterproof membrane 325 by use ofadhesive 328. A waterproof membrane 330 is adhered to the top of thegreen roof 310. A plurality of environmentally responsible insulatingconstruction blocks for green decking application that have been toppedwith a permeable fireproof material 345, such as coated expanded slate,are placed on top of a layer of grout 355 to adhere to the waterproofmembrane 330 to form a green deck 350. Green deck 350 may compriseartificial turf 397 that can be bonded to the top of the layer offireproof permeable material 345.

FIG. 3D depicts a cut-away view of one embodiment of an environmentallyresponsible insulating construction block for green roofing applicationtopped with an environmentally responsible insulating construction blockfor green decking application comprising pavers or tile. Environmentallyresponsible insulating construction blocks for green roofing applicationare adhered on top of a roofing substrate 320 with a layer of grout 312to form a green roof 310. A waterproof membrane 330 is adhered to thetop of the green roof 310. A plurality of environmentally responsibleinsulating construction blocks of coated shredded rubber tire pieces forgreen decking application that have been topped with a permeablefireproof material 345, such as expanded slate, are placed on top of alayer of grout 355 to adhere to the waterproof membrane 330 to form agreen deck 350. Green deck 350 may comprise pavers or tiles 390 bondedto the top of the layer of fireproof permeable material 345 withadhesive 392.

FIG. 3E depicts a cut-away view of one embodiment of an environmentallyresponsible insulating construction block for green roofing applicationtopped with an environmentally responsible insulating construction blockfor green decking application comprising pavers or tile. In thisembodiment, environmentally responsible insulating construction blocksfor green roofing application are adhered to an insulation board 327 andthen adhered on top of a roofing substrate 320 using adhesive 328 toform a green roof 310. A waterproof membrane 330 is adhered to the topof the green roof 310. A plurality of environmentally responsibleinsulating construction blocks of coated shredded rubber tire pieces forgreen decking application that have been topped with a permeablefireproof material 345, such as coated expanded slate, are placed on topof a layer of grout 355 to adhere to the waterproof membrane 330 to forma green deck 350. Green deck 350 may comprise pavers or tiles 390 bondedto the top of the layer of fireproof permeable material 345 withadhesive 392.

FIGS. 4A-4J depict the steps of manufacturing environmentallyresponsible insulating construction blocks for green roofing applicationaccording to one embodiment of the invention.

In FIG. 4A, a dry mixture is made from silica fume, slag cement andcement.

In FIG. 4B, shredded rubber tire pieces are added to the dry mixture andmixed until coated.

In FIG. 4C, water is added to the dry mix of coated shredded rubber tirepieces until the dry mix is fully wetted.

In FIG. 4D, a second dry mixture is made from silica fume, slag cementand cement.

In FIG. 4E, pieces of a fireproof material such as expanded slate areadded to the second dry mixture and mixed until coated.

In FIG. 4F, water is added to the dry mix of coated fireproof materialuntil the dry mix is fully wetted.

In FIG. 4G, molds are prepared and a layer of the wetted fireproofmaterial mix is added to the bottom of each mold.

In FIG. 4H, the wetted shredded rubber mix is added into each mold ontop of the wetted fireproof material mix.

In FIG. 4I, each mold is fitted with a lid and left to sit in ambientair until dry.

In FIG. 4J, the dried environmentally responsible insulatingconstruction blocks are removed from the molds and are ready for use.

FIG. 4K depicts an alternative mold form, showing a sloped bottom sothat the bottom surface of the environmentally responsible insulatingconstruction blocks for use as in a green decking applicationcorresponds to the tapering of the tops environmentally responsibleinsulating construction blocks for use as in a green roofingapplication.

The order of mixing of ingredients may be altered as desired by theoperator. For example, the shredded rubber tire pieces or waterproofmaterial, such as expanded slate, expanded slate may be placed in themixer, then the dry mixture of silica fume, slag cement and cement maybe added prior to mixing.

FIGS. 5A-5H depict the steps undertaken in the construction of astructure made entirely of an environmentally responsible insulatingmixture of shredded rubber tire pieces coated with silica fume, slagcement and cement, and mixed with water prior to monolithic pouring ofthe structure.

FIG. 5A depicts bags 505 filled with shredded rubber tire pieces 205having nominal size of greater than approximately 1 inch but smallerthan approximately 2 inches and containers 510 filled with a mix ofsilica fume, slag cement and cement.

FIG. 5B depicts bags 505 filled with shredded rubber tire pieces 205being added to a mixer 515, wherein they are mixed and thereafter theremaining dry ingredients (silica fume, slag cement and cement) areadded and mixed to coat the shredded rubber tire pieces 205.

In FIG. 5C, water 520 is added to the coated shredded rubber tire piecesin mixer 515 and mixed.

In FIG. 5D, wall molds 525 are built for the walls 527 of the structureupon a foundation, with a layer of grout 530 placed on the foundation535 at the bottom of each mold. A roof structure 529 is built atop thewall molds 525. Metal rods are placed inside each mold and on the roofstructure.

In FIG. 5E, wetted coated shredded rubber tire mix 540 is poured intothe wall molds 525.

In FIG. 5F, wetted coated shredded rubber tire mix 540 is poured atopthe roof structure 529.

In FIG. 5G, a plywood cover 545 is placed on top of the wetted coatedshredded rubber tire mix 540 that has been poured atop the roofstructure 529 and is attached to metal rods 550, wherein the cover 545is tightened to compress the wetted coated shredded rubber tire mix 540during drying.

In FIG. 5H, once the wetted coated shredded rubber tire mix 540 isdried, the cover 545 and molds 525 are removed and a structure made ofan environmentally responsible insulating mixture of shredded rubbertire pieces coated with silica fume, slag cement, cement and water isformed.

FIG. 6 depicts one embodiment of a green roofing application 600comprising environmentally responsible insulated construction blocks610. The green roofing application 600 comprises a low slope roofstructure 620 that includes a metal or concrete deck 630 and a pluralityof environmentally responsible insulated construction blocks 610.

Environmentally responsible insulated construction blocks 610 areattached to the metal or concrete deck 630 using high strengthself-setting grout 640, and a waterproof membrane 650 is disposed on anadhesive or glue layer 625 that is disposed on the top surfaces 615 ofthe environmentally responsible insulated construction blocks 610.

In one embodiment, waterproof membrane 650 comprises any membrane knowntoday or later developed for roofing or other construction purposes.Waterproof membrane 650 may vary according to the use and the climate ofthe construction.

FIGS. 7A-7G depict the steps of manufacturing environmentallyresponsible insulating construction blocks according to one embodimentof the invention.

In FIG. 7A, a dry mixture is made from silica fume, slag cement andcement.

In FIG. 7B, shredded tire pieces are added to the dry mixture and mixeduntil coated.

In FIG. 7C, water is added to the dry mix until the dry mix is fullywetted.

In FIG. 7D, molds are prepared and a layer of grout is added to thebottom of each mold.

In FIG. 7E, the wetted mix is added into each mold until full.

In FIG. 7F, each mold is fitted with a lid and left to sit in ambientair until dry.

In FIG. 7G, the dried environmentally responsible insulatingconstruction blocks are removed from the molds and are ready for use.

EXAMPLES

The following examples illustrate the manufacture and characteristics ofenvironmentally responsible insulated construction blocks in furtherdetail. These examples are exemplary only and in no way limit or areintended to limit the scope of this invention.

Example 1

Manufacture of an Environmentally Responsible Insulated ConstructionBlock For Green Decking Application.

Approximately 1 gallon of silica fume weighing 6.4 lbs., approximately 1gallon of slag cement weighing 9.2 lbs. and approximately 1.5 gallons ofPortland cement weighing 15.3 lbs. were mixed together for at least 2minutes. Rubber tires were shredded to a size range of approximately ½″to 2 inches wherein the steel from the tires was removed but nylon fromthe tires remained in the shredded rubber tire pieces. Seventy-five (75)lbs. of the shredded tire pieces were added to the mix, and theresulting mixture was mixed for another five (5) minutes. Thereafter, 2gallons of water were added to wet the dry shredded rubber tire mixture.

Separately, 3 gallons of expanded slate was mixed with 25.6 oz. slagcement, 25.6 oz. silica fume and 38.4 oz. Portland cement were mixedtogether for at least five (5) minutes. Thereafter, 51.2 oz. water wereadded to wet the dry expanded slate mixture.

A layer of the wetted shredded rubber tire mixture was poured into moldssized 12 inches by 12 inches by 4 inches deep to which approximately 1inch of the wetted expanded slate mixture had previously been added. Themolds were filled and a lid closed over the mold and left to dry for 5days at room temperature in the ambient environment. Once the mixturewas dry in each mold, the resulting environmentally responsibleinsulated construction blocks were removed and were ready for use ingreen decking applications.

Example 2

Environmentally responsible insulated construction blocks for greendecking application were prepared as in Example 1 except that the bottomof the mold is sloped.

The dried environmentally responsible insulated construction blocks havea sloped top surface comprising expanded slate.

Example 3 [Manufacture of an Environmentally Responsible InsulatedConstruction Block For Green Roofing Application.]

Environmentally responsible insulated construction blocks for greenroofing applications were prepared by mixing together 1 gallon of silicafume weighing 6.4 lbs., approximately 1 gallon of slag cement weighing9.2 lbs. and approximately 1.5 gallons of Portland cement weighing 15.3lbs. for at least 2 minutes. Rubber tires were shredded to a size rangeof approximately ½″ to 2 inches wherein the steel from the tires wasremoved but nylon from the tires remained in the shredded rubber tirepieces. Seventy-five (75) lbs. of the shredded tire pieces were added tothe mix, and the resulting mixture was mixed for another five (5)minutes. Thereafter, 2 gallons of water were added to wet the dryshredded rubber tire mixture. When the mixture was fully wetted, themixture was poured into molds sized 12 inches by 12 inches and having athickness of around 4 inches to which ½ inch of grout had previouslybeen added. The molds were filled and a lid closed over the mold andleft to dry for 5 days at room temperature in the ambient environment.Once the mixture was dry in each mold, the resulting environmentallyresponsible insulated construction blocks were removed and then attachedto the metal or concrete deck of the top of a building using highstrength self-setting grout. A waterproof membrane was disposed on anadhesive or glue layer that was disposed on the top surfaces of theenvironmentally responsible insulated construction blocks. Thereafter aplurality of the environmentally responsible insulated constructionblocks prepared as in Example 2 were adhered to the waterproof membranein a green roofing application.

Example 4

The environmentally responsible insulated construction blocks for greendecking application were tested alone and as attached to various roofingsystems, and also environmentally responsible insulated constructionblocks for green roofing application as described in Example 3 for thefollowing: wind uplift testing; Class A fire rating; field withdrawalresistance testing; metal edge attachment testing; sound transmissionloss; compression testing; steady-state thermal transmission properties;flow of water; age testing; and recycled content, as well as physicalproperties testing. The results are presented below.

TAS 114-95 Wind uplift testing.

Environmentally responsible insulated construction block for greenroofing application adhesive foam attached to 2″ extruded polystyreneinsulation—at 502.5 PSF no failure recorded

Environmentally responsible insulated construction block for greendecking application over environmentally responsible insulatedconstruction block for green roofing application adhesive foam attachedto 2″ polystyrene insulation—failure at 387.5 PSF

Paver on environmentally responsible insulated construction block forgreen decking application over environmentally responsible insulatedconstruction block for green roofing application attached to concreteslab with grout—failure at 400 PSF

Artificial turf on environmentally responsible insulated constructionblock for green decking application over environmentally responsibleinsulated construction block for green roofing application attached toconcrete slab with grout—failure at 330 PSF

Environmentally responsible insulated construction block for greenroofing application attached to concrete slab via grout—failure at 222.5PSF

Paver on environmentally responsible insulated construction block forgreen decking application over environmentally responsible insulatedconstruction block for green roofing application adhesive foam attachedto 2″ polystyrene insulation—failure at 300 PSF

UL 790 Class A Fire Rating.

4″ environmentally responsible insulated construction block for greenroofing application at infinite slope 1 ½ ft. no ignition test—PASS

4″ thick environmentally responsible insulated construction block forgreen decking application with artificial turf slope ¼″. Melt on testsample is 30 inches no ignition test—PASS

4″ thick environmentally responsible insulated construction block forgreen decking application with artificial turf slope ¼″. Melt on testsample is 27 inches no ignition test—PASS

4″ thick environmentally responsible insulated construction block forgreen roofing application at 3″ slope. Surface char 2 ft. no ignitiontest—PASS

TAS-105 Field Withdrawal Resistance Testing.

Ten environmentally responsible insulated construction block for greendecking application were tested for Withdrawal Resistance Testing.Fastener used 3-½″ Spade Point Headlok Fastener by Olympic Fasteners,Inc. The selected estimator value “t” based on statistical 95%probability Tvp=2.262. The calculated mean FM=a/N(Sum Fi)=364.0. Thecalculated standard deviation (SF)=Sqrt[((1/N−1)(Sum(Fi−FM)̂2))]=110.294. The % deviation (PD)=30.30%. According to TAS105-11 (FBC 2114 & FM 1-52), F2014=FM−(Tvp)(SF/Sqrt N), hereF2014=285.11. The MCRF14 (Minimum Characteristic ResistanceForce)=F2014=285.11.

TAS-111(B)-95 Metal Edge Attachment Testing.

Environmentally responsible insulated construction block for greenroofing application was tested by PRI Construction MaterialsTechnologies, Inc. for the pullout values of a drip edge. Horizontalloads were applied in 50 lbf increments for 60 seconds beginning with a300 lbf load. After each loading interval, the load was reduced to zeroand maintained for 120 seconds prior to incrementing the load andadditional 50 lbf load. The average failure load was 350 lbf, withmaximum pressure of 1050 psf.

ASTM E90-09 Sound Transmission Loss.

Environmentally responsible insulated construction block for greenroofing application STC=39 OITC=36

ASTM C39 Compression Testing.

Environmentally responsible insulated construction block for greenroofing application

7 Days 80 PSI

28 Days 89 PSI

28 Days 96 PSI

56 Days 94 PSI

Environmentally responsible insulated construction block for greendecking application

7 Days 96 PSI

28 Days 89 PSI

28 Days 83 PSI

56 Days 87 PSI

ASTM C-518 Standard Test Method of Steady-State Thermal TransmissionProperties by means of Heat Flow Meter Apparatus.

Environmentally responsible insulated construction block for greenroofing application R-Value=1.3127 per inch

UL Flow Rate of Water Passing Thru Environmentally Responsible InsulatedConstruction Blocks for Green Decking Application.

4″ Thick environmentally responsible insulated construction block forgreen decking application

Prewetting Time Elapsed 20 Seconds, 8 LBS of water poured, 7.4 lbs ofwater collected, 0.6 lbs water retained

Testing Time Elapse 35 Seconds, 40 lbs of water poured, 38.7 lbs ofwater collected, 1.3 lbs water retained

12″ Thick Sample

Prewetting Time Elapsed 55 seconds, 8 lbs of water poured, 6.6 lbscollected, 1.4 lbs of water retained

Testing Time Elapsed 65 Seconds, 40 lbs of water poured, 38.4 lbs watercollected, 1.6 lbs of water absorbed.

Age Testing.

Environmentally responsible insulated construction block for greenroofing application was tested at PRI Construction MaterialsTechnologies, Inc. for aging by exposure to UV light at a constanttemperature for 5000 hours under AC 48 UV light.

Physical Properties Testing.

Environmentally responsible insulated construction block for greenroofing application was tested at PRI Construction MaterialsTechnologies, Inc. for physical properties testing, specificallyflexural strength of concrete using ASTM C293-16 and for ImpactResistance under UL 2218.

ASTM C293—Pre-weathering: 367 lbs.; post-weathering: 415 lbs. (5000 hrs.AC 48 UV weathering)

UL2218 Class 4 Impact Hail Test (Steel Ball)—Passed

Recycled Content.

Environmentally responsible insulated construction block for greenroofing application and environmentally responsible insulatedconstruction block for green decking application were both certified bySCS Global Services for recycled content.

-   -   Environmentally responsible insulated construction block for        green roofing application—4″ thick—87.53% recycled content by        volume

Environmentally responsible insulated construction block for greenroofing application—8″ thick—90.57% recycled content by volume

Environmentally responsible insulated construction block for greendecking application—4″ thick—80.59% recycled content by volume

Environmentally responsible insulated construction block for greendecking application—4″ thick—86.18% recycled content by volume

Maximum Design Pressure (Steel Deck).

A plurality of environmentally responsible insulated construction blocksfor green roofing application having a ¼″ slope was adhered using AH-160propack adhesive continuous 1-½ inch beads spaced 6″ O.C. to min. 22 GA1.5″ Type B galvanized steel deck. An 8000 psi structural concretesurface was adhered to the top surface of the plurality ofenvironmentally responsible insulated construction blocks for greenroofing application to which was applied a NOA-approved fully adheredroofing system. The maximum design pressure measured was −292.5 psf.

Example 5

A structure having four walls and a roof was built using the coatedshredded rubber tire mixture of EXAMPLE 3. A scarified concrete slab waspoured as the base of the structure. Molds for walls of about twelve(12) inches thickness were constructed and a layer of grout was placedover the scarified concrete slab at the base of the molds. Metal rodswere inserted from the base to extend beyond the tops of the molds. Aplywood sheet was placed on top of the poured coated shredded rubbertire mixture to provide compression to the mixture while it dried. Aroof structure was built on the top of the walls using plywood. A layerof the coated shredded rubber tire mixture twelve (12) inches thick waspoured on the plywood layer to form the roof. The roof was thereaftercoated with stucco and roof paint. A plurality of rods extended upwardfrom the plywood layer to allow for a top to be placed over the pouredcoated shredded rubber tire mixture to compress it while it dried.

The structure comprising was tested and found to have a load bearingcapacity of 20,106 lbs. During testing, the structure sagged ¼ inch dueto weight load but the sag decreased to ⅛ inch when the weight wasremoved. The structure was measured to have an R-value of 15.72 with arecycled content of about 93.83%.

In the foregoing description, the invention has been described withreference to specific exemplary embodiments thereof. It will be apparentto those skilled in the art that a person understanding this inventionmay conceive of changes or other embodiments or variations, whichutilize the principles of this invention without departing from thebroader spirit and scope of the invention. The specification anddrawings are, therefore, to be regarded in an illustrative rather than arestrictive sense.

1. An environmentally responsible insulated construction blockcomprising: a plurality of shredded rubber tire pieces coated withsilica fume, slag cement and cement forming a block having a topsurface, a bottom surface substantially parallel to the top surface and4 side surfaces substantially perpendicular to the top surface and thebottom surface, wherein the block has a depth defined by the distancebetween the top surface and the bottom surface; wherein the shreddedrubber tire pieces range in size of between about ½ inch to 2 inches,wherein the shredded rubber tire pieces comprise at least 50% by weightof the shredded rubber tire pieces, silica fume, slag cement and cement,wherein the environmentally responsible insulated construction blockforms an open interior matrix structure.
 2. The environmentallyresponsible insulated construction block of claim 1, further comprisingone or more layers of grout disposed on the exterior of the top surface,the bottom surface or both the top and the bottom surfaces.
 3. Theenvironmentally responsible insulated construction block of claim 1,wherein the block is about 12 inches square.
 4. The environmentallyresponsible insulated construction block of claim 3, wherein thethickness of the block is greater than about 2 inches.
 5. Theenvironmentally responsible insulated construction block of claim 4,wherein the thickness of the block is about 4 inches.
 6. Theenvironmentally responsible insulated construction block of claim 4,wherein the thickness of the block is between about 2 inches and about20 inches.
 7. The environmentally responsible insulated constructionblock of claim 2, wherein the block is used in a roofing system.
 8. Theenvironmentally responsible insulated construction block of claim 1, foruse in construction of a wall, a deck or a walkway. 9-20. (canceled) 21.The environmentally responsible insulated construction block of claim 7,wherein the roofing system comprises a low slope roofing system.